Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
  • B29C51/26—Component parts, details or accessories; Auxiliary operations
  • B29C51/266—Auxiliary operations after the thermoforming operation
  • B29C51/268—Cutting, rearranging and joining the cut parts
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
  • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
  • B25J11/00—Manipulators not otherwise provided for
  • B25J11/005—Manipulators for mechanical processing tasks
  • B25J11/006—Deburring or trimming
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23C—MILLING
  • B23C3/00—Milling particular work; Special milling operations; Machines therefor
  • B23C3/12—Trimming or finishing edges, e.g. deburring welded corners
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
  • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
  • B25J15/00—Gripping heads and other end effectors
  • B25J15/06—Gripping heads and other end effectors with vacuum or magnetic holding means
  • B25J15/0616—Gripping heads and other end effectors with vacuum or magnetic holding means with vacuum
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B26—HAND CUTTING TOOLS; CUTTING; SEVERING
  • B26D—CUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING
  • B26D3/00—Cutting work characterised by the nature of the cut made; Apparatus therefor
  • B26D3/02—Bevelling
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
  • B29C51/26—Component parts, details or accessories; Auxiliary operations
  • B29C51/261—Handling means, e.g. transfer means, feeding means
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
  • B29C51/26—Component parts, details or accessories; Auxiliary operations
  • B29C51/44—Removing or ejecting moulded articles
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
  • B29C51/26—Component parts, details or accessories; Auxiliary operations
  • B29C51/44—Removing or ejecting moulded articles
  • B29C51/445—Removing or ejecting moulded articles from a support after moulding, e.g. by cutting
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
  • B29C51/26—Component parts, details or accessories; Auxiliary operations
  • B29C51/46—Measuring, controlling or regulating
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C2793/00—Shaping techniques involving a cutting or machining operation
  • B29C2793/0027—Cutting off
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C2793/00—Shaping techniques involving a cutting or machining operation
  • B29C2793/009—Shaping techniques involving a cutting or machining operation after shaping
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
  • B29K2023/04—Polymers of ethylene
  • B29K2023/06—PE, i.e. polyethylene
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
  • B29K2023/10—Polymers of propylene
  • B29K2023/12—PP, i.e. polypropylene
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2033/00—Use of polymers of unsaturated acids or derivatives thereof as moulding material
  • B29K2033/04—Polymers of esters
  • B29K2033/12—Polymers of methacrylic acid esters, e.g. PMMA, i.e. polymethylmethacrylate

Definitions

• This invention is in the field of contoured polymeric panels.
• New architectural building designs are increasingly featuring contoured external shapes. This in turn brings challenges to efficiently produce architectural cladding or fagade panels particularly when the building design specifies a plurality of one-off double- curved panels. A further trend is to replace concrete structures with lighter weight polymeric materials.
• United States patent application publication 2004/ 0104506A1 to Schelmbauer et al. describes a robotic method and apparatus for removing finished parts from a trim press of a thermoforming system including a pick and place tool mechanism moveable on at least a two-axis gantry mechanism arranged adjacent the trim press, the pick and place tool being moveable into and out of the trim press to acquire and remove finished thermoformed parts from the trim press. Movement of the pick and place tool is synchronized with the trim press cycle.
• the method may include a conveyance system mounted adjacent the pick and place mechanism for placing and stacking the finished thermoformed parts thereon once such parts are removed from the trim press. There remains a need to provide further efficiency gains in contoured panel forming operations such as panel trimming.
• Figure 1 is a block diagram of a process for making a contoured polymeric panel.
• Figure 2 shows exemplary trimmed edge shapes.
• thermoformable polymeric material may be used for the panel.
• the polymeric material is polyethylene (PE) or polypropylene (PP) or unfilled polymethyl methacrylate (uPMMA), filled polymethyl methacrylate (fPMMA) or unsaturated polyester.
• PE polyethylene
• PP polypropylene
• uPMMA unfilled polymethyl methacrylate
• fPMMA filled polymethyl methacrylate
• unsaturated polyester an exemplary filled polymethyl methacrylate is Cohan® which is available from DuPont Safety and Construction Inc., Wilmington, DE.
• thermoformed panel of this invention is a contoured panel, i.e., it is not flat.
• exemplary contoured panels are single or double curvature panels.
• single curvature is meant that the panel curves in only one direction, either upwards or downwards.
• double curvature is meant that the panel curves in two directions both downwards and upwards.
• Figure 1 provides an overview of a process for making a contoured polymeric panel such as a double curvature panel.
• the panel feedstock is a flat sheet of a necessary length, width and thickness such that finished panel shape and dimensions can be achieved.
• the shape of the panel feedstock will vary depending on the shape of the finished panel. Exemplary feedstock panel shapes are triangular, square, rectangular, pentagonal, hexagonal etc.
• step 1 the panel feedstock is placed in heating oven to preheat the panel and make the panel pliable.
• the temperature of the oven and dwell time of the panel in the oven will vary depending on the panel composition and thickness. Typical preheating temperatures are from 100 to 170 °C and dwell times from 5 to 15 minutes.
• step 2 the lower surface of the panel is placed on the lower half of a thermoforming vacuum molding tool and the upper half of the tool then positioned over the upper surface of the panel to close the tool.
• Any suitable vacuum molding tool may be used, for example an adaptive surface mold such a technique being well known in the plastic molding art.
• the panel remains in the tool for enough time to allow the panel to fully conform to the desired shape, this time being determined by the panel composition, panel thickness and type of tool.
• Typical processing conditions for this step are pressures of from 0.5 - 1 .5 bar, preferably about 0.8 bar and press times of from 5 - 30 minutes. After the desired dwell time in the mold, the mold is cooled such that the temperature of the panel is well below its glass transition temperature.
• step 3 after molding has been completed, the upper half of the tool is removed to reveal the contoured thermoformed panel.
• the panel is then removed from the mold.
• This removal process is achieved by attaching a robotic arm holding means to the thermoformed panel and then removing the panel from the mold by the robotic arm holding means.
• the robotic arm holding means comprises suction cups located at the extremity of the robotic arm.
• step 4 the robotic arm holding means repositions the panel over a trimming table, the table comprising a cutting router affixed to the table bed.
• the robotic arm holding means moves the panel relative to the cutting router in directions to trim all edges of the panel to required panel dimensions.
• the directional movement of the robotic arm is controlled by input from 3-dimensional drawing software of the final shape of the thermoformed panel, Panel edges may be straight or curved (chamfered) as shown by examples in Figure 2.
• 2a is a square edge trim and 2b and 2c curved edge trims.
• step 5 the robotic arm moves the trimmed panel to a panel collection station and deposits the trimmed panel at the collection station
• the robotic arm holding means may position the panel at a drilling station and move the panel such that holes are drilled at desired positions either partially or fully through the panel. This step may be completed before or after the edge trimming operation of step 4.
• Panel composition, dimensions and processing conditions are shown in Table 1. A number of different conditions was tried for some of the panels. Trimmed panel edge quality was a visual assessment. If the trimmed edge was smooth the quality was deemed to be good. Table 1
• This method of trimming highly contoured panels finds utility in external cladding panels, internal cladding panels, furniture, sculptures and other applications.
• the trimmed edges are of sufficient quality that adjacent panels may be adhesively bonded at the edges.
• the panels may be fixed to the article structure by screws, bolts, pins, adhesives, tapes or other fixing means.

Landscapes

• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Robotics (AREA)
• Life Sciences & Earth Sciences (AREA)
• Forests & Forestry (AREA)
• Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
• Moulds For Moulding Plastics Or The Like (AREA)
• Finishing Walls (AREA)

Priority Applications (5)

Applications Claiming Priority (2)

Publications (1)

Family

ID=77627504

Family Applications (1)

Country Status (7)

Citations (3)

Family Cites Families (10)

• 2020
  • 2020-08-06 US US16/986,406 patent/US12070894B2/en active Active
• 2021
  • 2021-07-22 WO PCT/US2021/042713 patent/WO2022031449A1/en not_active Ceased
  • 2021-07-22 JP JP2022577204A patent/JP7774005B2/ja active Active
  • 2021-07-22 EP EP21765748.5A patent/EP4192668B1/en active Active
  • 2021-07-22 KR KR1020227041013A patent/KR20230049058A/ko active Pending
  • 2021-07-22 CN CN202180057332.1A patent/CN116615326A/zh active Pending
  • 2021-07-22 CA CA3179986A patent/CA3179986A1/en active Pending

Patent Citations (3)

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